Method and apparatus for manufacturing hinges

ABSTRACT

The instant invention is a method and apparatus for assembling two hinge leaves. The apparatus includes an assembly for feeding a predetermined length of a wire pintle into a shear assembly. The shear assembly cuts the wire pintle to a specified length and locates the wire in a channel. Substantially simultaneously with the shearing of the wire, a punch and die assembly adjacent the shear assembly locates the two leaves of the hinge such that the barrels of the hinge are aligned. Once in position, a linear actuator drives the sheared length of wire pintle into the aligned hinge barrels to couple the two hinge leaves together. Once the pintle has been inserted, staking pins within the punch and die assembly impact select ones of the hinge barrels to keep the pintle in place. Also, disclosed is a novel method of manufacturing the two hinge leaves.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is related to provisional patent application serial No. 60/284,752, filed on Apr. 18, 2001, the contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] This invention relates generally to a method and apparatus for assembling components, and more particularly to a method and apparatus for manufacturing and assembling hinges.

[0004] 2. Description of the Related Art

[0005] Traditionally, hinges were made individually. Each leaf of the hinge was either hand-cut or stamped from a metal black and each of the individual hinge knuckles were rounded over a pre-positioned pintle by hammer or one or more press operations. Later, with mass production, the hinge leaves were stamped from a metal blank in a series of punch and die presses. Numerous such methods contemplated placing a pintle along the tabs which were progressively rounded around the pintle. To expedite the process, others formed used a continuous forming process where two hinge leaves were formed with the knuckles formed around a continuous length of wire pintle. At predetermined intervals, the hinges were stamped from the continuous hinge to form the desired length.

[0006] The problem most often associated with the continuous forming method is that subsequent steps formed on the hinge leaves often had an impact on other dimensions of the hinge. For example, some steps contemplate punching the fastener holes after the pintle has been placed. The punching steps often times deforms the plates with some extension to the knuckles or barrels. Such deformation results in the hinge not swinging smoothly. Others cut the hinge to length also after the pintle has been trapped. This shearing method of the entire hinge assembly also introduces similar contortions and deformations in the assembly, also resulting in poor operation. Moreover, the continuous operations are problematic when an operation problem occurs, or tools are changed. What results is a shut down of the entire hinge manufacturing process until the fix is corrected or the tools are changed. Moreover, there is substantial waste in time and material associated with such breakdowns or changes.

[0007] There has been a long felt and unfilled need to provide a much more efficient and cost-effective way of manufacturing hinges with fewer defects and at a cost competitive with mass production systems. The instant invention solves those needs.

SUMMARY OF THE INVENTION

[0008] The instant invention is a method and apparatus for assembling two hinge leaves. The apparatus includes an assembly for feeding a predetermined length of a wire pintle into a shear assembly. In one embodiment, a shear assembly cuts the wire pintle to a specified length and locates the wire in a channel. In a second embodiment, a magazine supplies pre-manufactured pintles. In both embodiments, a punch and die assembly adjacent the feed assembly locates the two leaves of the hinge such that the barrels are aligned. Once in position, a linear actuator drives the wire pintle into the aligned hinge barrels to couple the two hinge leaves together. Once the pintle has been inserted, staking pins within the punch and die assembly impact select ones of the hinge barrels to keep the pintle in place. Also, disclosed is a novel method of manufacturing the two hinge leaves.

[0009] According to one aspect of the invention, an apparatus is provided for interconnecting two leaves of a hinge by automatically inserting and clamping a pin in the barrels of at least two leaves, comprising in combination a first assembly for holding the two hinge leaves together such that the barrels of the two hinge leaves are aligned; a feed assembly for providing a predetermined length of wire for use as a pintle; and a second assembly for receiving the length of wire from the feed assembly and driving the length of wire into the aligned barrels of the two hinge leaves.

[0010] In a further form of the invention, the first assembly includes a frame assembly; a press attached to the frame assembly; and a punch and die assembly disposed beneath the press for receiving the two leaves of the hinge. The feed assembly may include a drive assembly for supplying the length of wire to the second assembly for use as a pintle; and a wire conditioner assembly for straightening the length of wire. The feed assembly alternatively may include a magazine containing at least one length of wire to be used as a pintle to be dispensed to the second assembly. The second assembly may include a frame assembly; a press attached to the frame assembly; and a shear assembly adjacent and acted upon by the press for receiving the length of wire and shearing the length of wire into the pintle. The punch and die assembly briefly mentioned above may include a seat for receiving the two leaves of the hinge in a predetermined configuration; a punch assembly having a housing and a staking tool for engaging the two leaves of the hinge on the seat and compressing predetermined portions of a hinge leaf knuckle about the pintle; and an assembly for ejecting the interconnected hinge leaves from the seat.

[0011] The invention also includes a method for assembling the two leaves of a hinge including the steps of locating and retaining within a first press assembly two leaves of a hinge in a predetermined configuration on a seat such that the barrels of the two hinge leaves are aligned; feeding a length of wire for use as a pintle to a second press assembly; and receiving the length of wire from the feed assembly and the second press assembly, and driving the length of wire into the aligned barrels of the two hinge leaves using a third press assembly. The locating step may further include the steps of providing a frame assembly for supporting a linear actuator in the first press assembly; and locating the two leaves of the hinge in a punch and die assembly disposed beneath the linear actuator for receiving the two leaves of the hinge. The feeding step may include drawing a predetermined length of wire from a spool of wire and supplying that length of wire to the second assembly; and conditioning the length of wire into a substantially straight configuration by removing any curvature. Alternatively, the feeding step may include providing a magazine containing at least one predetermined length of pintle to be dispensed to the third assembly. The feeding step may farther include supplying the length of wire to a shear assembly; shearing the length of wire to form a pintle; and driving the pintle into the aligned barrels of the two hinge leaves. Moreover, the step of locating the two leaves of the hinge in a punch and die assembly may include positioning the two leaves of the hinge in a predetermined configuration on a seat; urging a housing against the two leaves of the hinge on the seat while driving the length of wire into the aligned barrels of the two hinge leaves by the third press assembly; and staking predetermined portions of at least one of the hinge barrels about the predetermined length of wire to hold it in the hinge.

[0012] According to another form of the invention a method is provided for forming a hinge assembly, and includes the steps of punching a first and second hinge leaves from a piece of stock, each of said hinge leaves having knuckles substantially formed thereon and configured to mate with like knuckles on the opposite leaf. Placing the first and second hinge leaves in a predetermined configuration on a seat and compressing the first and second hinge leaves on the seat between a punch and die such that the knuckles are aligned. Once aligned, ramming a pintle into the knuckles of the first and second hinge leaves when compressed between said punch and die. Finally, staking predetermined ones of the knuckles so as to positively fix the pintle therein. The method may further include the steps of drawing a length of wire from a spool of wire and conditioning the length of wire to remove any curl or bends. Following conditioning, feeding the length of wire into a measuring station to define a predetermined length of wire. From there, shearing the predetermined length of wire to form the pintle. Finally, aligning the pintle axially with the knuckles prior to the step of ramming. The method may further include preforming a plurality of pintles, loading the plurality of pintles into a magazine, placing the magazine into a receiver, and dispensing one of the plurality of pintles into a position axially aligned with the knuckles prior to the step of ramming.

[0013] In another form of the invention, a seat is configured to receive a first and second hinge leaves in a predetermined configuration such that the knuckles of each hinge leave are aligned. A punch and die exists on opposite sides of the seat for placing the first and second hinge leaves in a predetermined and fixed orientation. A first ram is located adjacent the punch and die for ramming a pintle into the aligned knuckles of the first and second hinge leaves when placed in that predetermined and fixed orientation. A second ram lies adjacent the seat for staking predetermined ones of the hinge knuckles so as to positively fix the pintle therein. The invention further includes an assembly for drawing a length of wire from a spool of wire, an assembly for conditioning the length of wire to remove any curl or bends, an assembly for feeding the length of wire into a measuring station to define a pintle length, an assembly for shearing the length to form the pintle, and an assembly for aligning the pintle axially within the knuckles. The invention may also include a magazine for retaining a plurality of preformed pintles. The magazine fits into a receiver which adjacent the first. The magazine also includes a dispensing member for depositing one of the plurality of pintles into a position axially aligned with the knuckles and with said first ram.

[0014] A better understanding of the invention will be attained by reference to the following drawing figures as well as the subsequent detailed written description of the different embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0015]FIG. 1 is a schematic side elevation of one embodiment of the invention;

[0016]FIG. 2 is a schematic plan view of the invention shown in FIG. 1;

[0017]FIG. 3 is an end elevation of the invention shown in FIG. 1;

[0018]FIG. 4 is an end view of the intermediate press assembly shown in FIG. 1;

[0019]FIG. 5 is a bottom plan view of the punch assembly shown in FIG. 3;

[0020]FIG. 6 is a plan view of the die assembly shown in FIG. 3;

[0021]FIG. 7 is an enlarged side elevation view of the shear assembly shown in FIGS. 1, 2, and 4;

[0022]FIG. 8 is an enlarged end section view of the shear assembly shown in FIG. 7;

[0023]FIG. 9 is a schematic side elevation of another embodiment of the invention;

[0024]FIG. 10 is a schematic plan view of the invention shown in FIG. 9;

[0025]FIG. 11 is an end elevation of the invention shown in FIG. 9; and

[0026]FIG. 12 is an end elevation of one embodiment of a drive mechanism for a portion of the invention shown in FIG. 9.

DESCRIPTION OF ONE EMBODIMENT OF THE INVENTION

[0027] For purposes of the following description, the terms “upper,” “lower,” “left,” “rear,” “front,” “vertical,” “horizontal” and derivatives of such terms shall relate to the invention as oriented in drawing FIG. 2. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. However, it is to be understood that the dimensions of the various components may be changed or altered in order to satisfy different requirements and components.

[0028] Referring generally to the attached drawing figures, an apparatus is provided for interconnecting two leaves of a hinge by automatically inserting and clamping a pin in the barrels of at least two leaves, comprising in combination a first assembly for holding the two hinge leaves together such that the barrels of the two hinge leaves are aligned; a feed assembly for providing a predetermined length of wire for use as a pintle; and a second assembly for receiving the length of wire from the feed assembly and driving the length of wire into the aligned barrels of the two hinge leaves. The first assembly may include a frame assembly; a press attached to the frame assembly; and a punch and die assembly disposed beneath the press for receiving the two leaves of the hinge. The feed assembly may include a drive assembly for supplying the length of wire to the second assembly for use as a pintle; and a wire conditioner assembly for straightening the length of wire. The feed assembly alternatively may include a magazine containing at least one length of wire to be used as a pintle to be dispensed to the second assembly. The second assembly may include a frame assembly; a press attached to the frame assembly; and a shear assembly adjacent and acted upon by the press for receiving the length of wire and shearing the length of wire into the pintle. The punch and die assembly briefly mentioned above may include a seat for receiving the two leaves of the hinge in a predetermined configuration; a punch assembly having a housing and a staking tool for engaging the two leaves of the hinge on the seat and compressing predetermined portions of a hinge leaf knuckle about the pintle; and an assembly for ejecting the interconnected hinge leaves from the seat.

[0029] In another form of the invention, a seat is configured to receive a first and second hinge leaves in a predetermined configuration such that the knuckles of each hinge leave are aligned. A punch and die exists on opposite sides of the seat for placing the first and second hinge leaves in a predetermined and fixed orientation. A first ram is located adjacent the punch and die for ramming a pintle into the aligned knuckles of the first and second hinge leaves when placed in that predetermined and fixed orientation. A second ram lies adjacent the seat for staking predetermined ones of the hinge knuckles so as to positively fix the pintle therein. The invention further includes an assembly for drawing a length of wire from a spool of wire, an assembly for conditioning the length of wire to remove any curl or bends, an assembly for feeding the length of wire into a measuring station to define a pintle length, an assembly for shearing the length to form the pintle, and an assembly for aligning the pintle axially within the knuckles. The invention may also include a magazine for retaining a plurality of pre-formed pintles. The magazine fits into a receiver which adjacent the first. The magazine also includes a dispensing member for depositing one of the plurality of pintles into a position axially aligned with the knuckles and with said first ram.

[0030] In one embodiment of the instant invention, a punch and die assembly may be disposed at one end of a progressive die assembly used to manufacture hinge leaves from a continuous sheet of material. Disposed at one end of the progressive die assembly is a spool containing a band of steel, aluminum, or plastic which passes through the various punch and die sets contained within the progressive die. Details on the progressive die assembly will not be provided in this description. However, the steps of the progressive die assembly in the manufacturing of the hinge described in greater detail below are considered to be novel, particularly when used in combination with the instant invention. Although a progressive die assembly is mentioned as carrying out the method of forming the hinge components, it is contemplated the manufacture of those same components may be carried out by hand or with separate machines to achieve the same result. However, one of the substantial benefits of the progressive die assembly is the faster, and substantially automated production of work pieces than should the steps be done separately.

[0031] Referring now specifically to drawing FIGS. 1-6, a punch and die assembly 20 includes a first press assembly 30 at one end, a second or intermediate press assembly 32, and a feed assembly 34 disposed at an opposite end. All three assemblies (30, 32, and 34) are preferably mounted to a work surface or table 36 disposed at a predetermined height above a reference plane such as the floor. The table 36 is preferably designed so as to receive one or more bins 38 positioned to receive finished work pieces. In one embodiment, bin 38 is shown disposed beneath the upper surface of the table 36 to receive finished work pieces through a hole in the work surface. However, the location of the receiving bin 38 may be adjacent assembly 20 as well.

[0032] In one embodiment of the invention, it is contemplated the first press assembly 30 (FIGS. 1 and 3) completes the final assembly process. Assembly 30 may include a frame assembly 40 formed from at least one, and preferably two uprights 42, 44 spaced from each other, each having a lower edge attached to the upper surface of the table 36. Each upright 42, 44 may also have a centralized opening 46. In the embodiment shown, the two uprights 42, 44 support a linear actuator 48 having a downwardly directed piston 50. The lower end of the actuator 48 may be retained by a collar 52 or other structure which is attached to the upper edge of the centralized opening in each upright 42, 44. It is contemplated that the linear actuator may be a conventional hydraulicly-driven actuator, although it is preferred an air-driven oil system be used.

[0033] Also mounted to the uprights 42,44 at a lower edge of the centralized opening 46, is a punch and die assembly generally designated by the numeral 54, the principal components of which are shown in greater detail in drawing FIGS. 5 and 6. In general, punch and die assembly 54 may include an upper platen 56 supported above a lower platen 58 by a plurality of telescoping and biased guides, columns or posts 60 intended to keep the two platens 56, 58 in registered alignment as one is moved toward the other. In this embodiment of the invention, it is designed such that the upper platen 56 moves relative to the lower platen 58 under the force of piston 50.

[0034] Mounted on the upper surface of the lower platen 58 may be a cradle or seat 62 which is configured to receive the mating halves or leaves of the hinge assembly described in greater detail below. Because the overall design of the invention is designed to function in a generally vertical plane, seat 62 is oriented substantially horizontally such that when the two hinge leaves are placed on the seat, the barrels of the two halves are received in registered alignment in the valley or bottom-most portion of the seat. The seat 62 preferably includes two or more optical or magnetic proximity sensors (not shown) which can be used to detect the placement and proper orientation of the two mating hinge leaves. Moreover, for that matter, optical or magnetic proximity sensors are preferably used at multiple locations throughout the invention to provide the position and/or status of the various components. It is anticipated that seat 62 may also be designed to be polarized—that is, receive the two hinge leaves only in a single configuration. Additionally, the coupling arrangement of the seat 62 to the lower platen 58 permits seats 62 of different dimensions to be used.

[0035] Attached to the upper platen 56 is a punch assembly 64 including a housing 66 for retaining a positioning press assembly 68. The positioning press assembly 68, in turn, includes a staking tool described in greater detail below. With the two leaves of the hinge assembly properly in position in the seat 62, the positioning press assembly 68 is lowered such that contours on the lower edge of the staking tool ensure the barrels of the two hinge leaves are aligned and facilitate the final staking of the leaves in the assembly.

[0036] Adjacent the first press assembly 30 is the second press assembly 32. The purpose of the second press assembly is to cut or shear a strand of wire to a predetermined length, and then drive the wire into the aligned barrels of the two hinge leaves. As best illustrated in the embodiment illustrated by drawing FIGS. 1, 2 and 4, the second press assembly may include its own frame assembly 70 formed by at least one, and preferably two uprights 72, 74 attached at their lower ends to the upper surface of the table 36. Interconnecting the upper ends of the uprights 72, 74 may be a cross member 76 (FIGS. 1 and 4) which in turn may be attached to a collar 78 supporting the lower end of a second linear actuator 80. Just as with linear actuator 48, actuator 80 includes a downwardly oriented piston 82.

[0037] Disposed beneath piston 82, and supported by the lower portion of uprights 72, 74 is shear assembly 84. Referring to FIGS. 7 and 8, the shear assembly 84 includes a V-shaped channel guide 86 centrally disposed within the shear assembly 84 and has one end 88 adjacent to and aligned with the cradle or seat 62. Moreover, the shear assembly 84 is mounted on the lower platen 58 in order to maintain the alignment and close proximity of the seat 62 with assembly 84. The channel guide 86 is preferably disposed directly beneath a biased shear plate 90 disposed in the upper end of shear assembly 84. The shear plate 90 may also be located just slightly above a horizontally disposed passage or port 92 through which the wire stock for the hinge pin (also known as a pintle) is received. Opposite port 92 is a gauge assembly 94 having an adjustable pin 96 provided to establish the length of the pintle to be sheared by plate 90. As the shear plate 90 is depressed by piston 82 to shear the pin extending beyond passage 92, the pin falls into the V-shaped channel guide 86.

[0038] Disposed at one end 98 of shear assembly 84 is a horizontally disposed actuator assembly 100. Actuator assembly 100 includes a carriage 102 attached to the end of a piston 104 which is provided to drive the pintle along the V-shaped channel guide 86 and into the aligned barrels of the hinge leaves. As illustrated in FIG. 4, the V-shaped channel guide 86 includes a longitudinal channel or slot 106 located at the bottom through which the carriage 102 passes, driven by the piston 104 located in a passage 107 disposed beneath the V-shaped channel guide assembly 86. The longitudinal slot 106 ensures that the carriage 102 is aligned with the guide pin and properly driven into the aligned barrels of the hinge assembly.

[0039] One embodiment of the feed assembly 34 is best illustrated in FIGS. 1 and 2. Feed assembly 34 may include a drive assembly 110 and a wire conditioning assembly 112. The drive assembly 110 preferably includes a motor 114 attached to a gear box or transmission 116, both of which are interconnected to an upright 118 by a mounting bracket 120. The upright 118, in turn, is coupled to the work surface or table 36 by a bottom plate 122 and bulkhead 124. Extending below the transmision 116 is a drive 126 having drive wheels 128 and 130 disposed on opposite sides of the incoming wire and configured to frictionally engage the wire so as to cause it to feed into shear assembly 84. In the drawing figures, two drive wheels 128, 130 are illustrated to advance the wire. However, it should be understood that alternate drive methods may also be used including a linearly moving rachet-type system or counter-rotating belt or track drive system which engages a substantially greater length of the incoming wire. No matter what drive system is elected, it should be further understood that the material provides a frictional engagement with the incoming wire in order to maximize the advance of the wire into the shear assembly 84.

[0040] Adjacent the drive assembly and located proximate the opposite end of the table 36 from the first press assembly 30 is the wire conditioning assembly 112. The purpose of the wire conditioning assembly is to straighten the wire prior to being feed in the shear assembly described above. The wire conditioning assembly 112 may include a base plate 134 for supporting an upright 136 bolstered by a bulkhead 138. Mounted to the upper end of the upright 136 may be a lower and upper jaw 140, 142 respectively. The lower jaw 140 may be attached to the upright 136 while the upper jaw 142 may be interconnected in registered alignment with the lower jaw 140 and spring biased such that the upper jaw is in a naturally open position with respect to the lower jaw 140. In the preferred embodiment, a clamp assembly 144 is pivotally coupled to the upper end of the upright 136 and includes a cam surface 146 adapted to engage the upper end of the upper jaw 142 to urge it into close relationship with the lower jaw 140. Mounted to the upper and lower jaws 140, 142 are a plurality of rollers 148, 149. The rollers 148 are laterally offset with respect to rollers 149 in a staggered relationship. Each of the rollers 148, 149 includes a circumferential groove intended to engage a surface of the incoming wire to remove any coil or curvature in the wire in a vertical plane.

[0041] Cantilevered from upright 136 and adjacent the upper and lower jaws 140,142 may be a horizontally disposed plate 150 which supports horizontally disposed jaws 152, 154. (See FIG. 2). The horizontally disposed jaws 152, 154, like the vertically disposed jaws 140, 142, support rollers 156, 158 configured to engage opposite sides of the incoming wire. The jaws 152, 154 are spring biased and aligned with each other such that jaw 152 may be moved with respect to jaw 154. In this manner, the rollers 156, 158 contact opposite sides of the incoming wire and straighten the wire, removing any coil or curvature in a horizontal plane such that the wire fed to drive wheels 128, 130 is substantially straight. A clamp 160 having a cam surface 162 and a locking nut 164 is used to engage and disengage jaw 152 to maintain it in a desired position.

[0042] To facilitate operation of the assembly, a microprocessor or computer control system (not shown) is integrated with the various components. As briefly mentioned above, the linear actuators 48, 80, 100 are preferably pneumatically driven oil systems. Moreover, the actuator 100 may also use a pneumatically driven system capable of providing sufficient force to drive the sheared pin into the aligned hinge barrels. The pilot valves driving the liner actuators as well as the motor 114 on the drive assembly 110 may be controlled by the computer control system. The computer control system is also preferably connected to all of the proximity sensors in the assembly for monitoring the operational position and status of any particular component. Details of this control system will not be disclosed herein as it is readily apparent that one of ordinary skill in the art of numerical controls could design any one of a number of different systems for controlling the automated process of the punch and die assembly.

[0043] To reduce the chance of injury to the operators, it is preferred that the entire assembly be enclosed within a cabinet where the access panels are interconnected with sensors, such that when opened, the system is shut down. It is anticipated one or more light curtains could be incorporated at the end of the assembly proximate the first press assembly to ensure that the operator's hands are clear of the assembly before operation. Again, other than briefly mentioning these components, they will not be described in detail.

[0044] The invention also includes a method for assembling the two leaves of a hinge including the steps of locating and retaining within a first press assembly two leaves of a hinge in a predetermined configuration on a seat such that the barrels of the two hinge leaves are aligned; feeding a length of wire for use as a pintle to a second press assembly; and receiving the length of wire from the feed assembly and the second press assembly, and driving the length of wire into the aligned barrels of the two hinge leaves using a third press assembly. The locating step may further include the steps of providing a frame assembly for supporting a linear actuator in the first press assembly; and locating the two leaves of the hinge in a punch and die assembly disposed beneath the linear actuator for receiving the two leaves of the hinge. The feeding step may include drawing a predetermined length of wire from a spool of wire and supplying that length of wire to the second assembly; and conditioning the length of wire into a substantially straight configuration by removing any curvature. Alternatively, the feeding step may include providing a magazine containing at least one predetermined length of pintle to be dispensed to the third assembly. The feeding step may further include supplying the length of wire to a shear assembly; shearing the length of wire to form a pintle; and driving the pintle into the aligned barrels of the two hinge leaves. Moreover, the step of locating the two leaves of the hinge in a punch and die assembly may include positioning the two leaves of the hinge in a predetermined configuration on a seat; urging a housing against the two leaves of the hinge on the seat while driving the length of wire into the aligned barrels of the two hinge leaves by the third press assembly; and staking predetermined portions of at least one of the hinge barrels about the predetermined length of wire to hold it in the hinge.

[0045] According to another form of the invention a method is provided for forming a hinge assembly, and includes the steps of punching a first and second hinge leaves from a piece of stock, each of said hinge leaves having knuckles substantially formed thereon and configured to mate with like knuckles on the opposite leaf. Placing the first and second hinge leaves in a predetermined configuration on a seat and compressing the first and second hinge leaves on the seat between a punch and die such that the knuckles are aligned. Once aligned, ramming a pintle into the knuckles of the first and second hinge leaves when compressed between said punch and die. Finally, staking predetermined ones of the knuckles so as to positively fix the pintle therein. The method may further include the steps of drawing a length of wire from a spool of wire and conditioning the length of wire to remove any curl or bends. Following conditioning, feeding the length of wire into a measuring station to define a predetermined length of wire. From there, shearing the predetermined length of wire to form the pintle. Finally, aligning the pintle axially with the knuckles prior to the step of ramming. The method may further include preforming a plurality of pintles, loading the plurality of pintles into a magazine, placing the magazine into a receiver, and dispensing one of the plurality of pintles into a position axially aligned with the knuckles prior to the step of ramming.

[0046] More specifically, in the operation of the invention, the punch and die assembly 20 may be disposed at the discharge end of the progressive die assembly, or alternatively, may be located elsewhere where the finished product from the progressive die assembly is delivered. In one embodiment, an operator, standing at the end of the punch and die assembly 20 proximate the first press assembly30, places opposing halves of the hinge into the cradle or seat 62 such that the barrels of the hinge leaves are aligned. Prior to actuating the system, the operator has already inserted one end of a spool of wire into the wire handling system 1 12, fed it through the drive system 110, and inserted it into the shear assembly 84 so that upon initiation of the system, the proper length of wire pin is loaded in the shear assembly 84 to stake the hinge.

[0047] Once the operator has the matching hinge leaves disposed within the cradle or seat 62, the operator depresses a switch causing the machine to cycle wherein the feed assembly 34 ensures the proper length of wire pin is disposed within the shear assembly 84. Upon confirmation by a proximity sensor the appropriate amount of wire has been feed into the shear assembly 84, linear actuator 80 drives piston 82 downwardly against shear plate 92 to shear the wire pin in shear assembly 84 and causing it to fall into V-shaped channel 86. Substantially simultaneously, the upper platen 56 of the first press assembly 30 is moved downwardly by linear actuator 48 to place the punch tool assembly 64 into engagement with the hinge barrels of the two hinge leaves located in the cradle 62. Once the upper platen 56 and punch assembly 64 locate the two hinge leaves, actuator 100 drives the wire pin in the V-shaped channel guide 86 into the aligned hinge barrels. At this point, the barrels of the hinge are ever so slightly open to easier receive the pintle therein. Substantially immediately following the insertion of the wire pin into the hinge barrels, staking pins disposed within the punch tool assembly 64 are actuated, causing them to depress certain ones of the interlocking hinge barrels to secure the pintle in place. Once the process is complete, and the proximity sensors indicate that the method has been completed, the upper and lower platens of the first press assembly separate wherein the hinge assembly may be removed manually, or in a preferred embodiment, is ejected from the cradle 62 by an actuator assembly (not shown) to fall through a hole in the table and into the bin 38. In this manner, the operator is already poised to insert another pair of matching hinge leaves on the cradle 62 for the next operation.

[0048] As briefly mentioned at the beginning of this description, it is believed the method of forming the hinge leaves in the progressive die assembly also presents a novel process. The progressive die assembly receives a continuous sheet of steel, inserted at one end wherein the first stamping creates an indexing hole in the steel. At the second position, the progressive die assembly punches bolt holes in the steel which will be used to attach the hinge to the substrate. Following the punch of the bolt holes, the conveyor indexes the sheet of steel to the third station where each of the holes is punched to create a chamfer. Following the chamfer, the conveyor indexes the sheet of steel to the fourth and fifth stations where the fingers for the hinge barrels are sequentially punched. It is at these two stages of the process where the perimeter of each hinge leaf is formed, interconnected to each other by a web of steel. When conveyed to the seventh through tenth stations of the progressive die assembly, the contours of each hinge leaf are formed as well as the progressive rolling of the fingers to produce the interlocking barrels of each hinge leaf. At the twelfth station, additional punches are added to specifically locate each hinge plate on the substrate. The fourteenth station is where the two hinge leaves are separated by punching out the web which also disconnects the hinge plates from the continuous sheet of steel.

[0049] The invention described above has included a continuous wire feed assembly, where the length of the wire is measured prior to being sheared, and then driven into the aligned barrels of the mating hinge leaves. However, it is contemplated the pintles of the hinge assembly may be prefabricated, rendering the need to measure and sheer the wire unnecessarily. This alternative is provided for in the alternate embodiment of the invention illustrated in FIGS. 9-12. For the sake of clarity, only those portions of the adjoining assembly will be shown for reference. For details on the adjoining assemblies, please refer to the FIGS. 1-6.

[0050] Referring to FIGS. 9-12, the alternate embodiment 200 of the invention presents a less complicated yet more versatile assembly. The most obvious modifications are the removal of the second or intermediate press assembly 32 as well the feed assembly 34 shown in FIGS. 1-6 and replaced with a magazine described below. Rather than a continuous wire feed, precut pintles are used for each hinge assembly. It is contemplated the pintles are pre-manufactured and delivered in bulk to the hinge assembly machine. For example, it is contemplated that steel rod of specific dimension is cut to predetermined lengths in a separate press and coated with a lubricant to facilitate insertion into the hinge barrels during the assembly process. In particular, it is contemplated each of the pintles may be coated with a polytetrafluoroethylene such as sold under the brand name Teflon available from DuPont Corporation. The coated pintles may then be packed in bulk and delivered to the hinge assembly location.

[0051] The alternate embodiment of the hinge assembly machine 200 includes a feed assembly 202 which includes a magazine 204 configured to receive and dispense a predetermined number of the pre-manufactured pintles. The magazine 204 may take on anyone of a number of different forms, but in general, includes a first box end 206 rigidly attached to a back plate 208, and a second opposing box end 210 spaced therefrom and configured for sliding movement along the back plate 208. Horizontally mounted to the back plate 208 are two spaced apart and parallel tracks 212, 214 which pass through corresponding channels 216,218 in box end 210 to help align box end 210 and keep it parallel to box end 206. The intermediate area between the two box ends 206, 210 is preferably open in order to permit the operator to grab hold of a quantity of pintles and remove them from the magazine 204 should it be necessary, such as making a change in pintle size, or re-filing the magazine.

[0052] As noted earlier, it is desirable for box end 210 to be translatable in a horizontal direction with respect to box end 206 and parallel to back plate 208, primarily to accommodate for preferred variations in the pintle size. Toward this end, a horizontal slot 220 is defined in back plate 208. In turn, a bolt 222 passes through box end 210 such that the threaded end 224 extends through slot 220. There, a crank 226 is received, and when turned, tightens the box end 210 and holds it in position.

[0053] Attached to the lower portion of the back plate 208 of the magazine 204 is a dispensing member 230. Preferably dispensing member 230 is in the form of a right circular cylinder having a longitudinal axis oriented horizontally and substantially directly below box ends 206 and 210. Coincident with the longitudinal axis of the dispensing member 230, and extending from opposite ends thereof are axles or spindles 232,234, each journaled in a bearing block 236,238, respectively. Each of the bearing blocks 236, 238 are in turn mounted to the back plate 208. Axle or spindle 234 shown in the right hand portion of FIG. 9 is slightly longer such that it extends beyond bearing block 238. There, the end of the spindle 234 is attached to a spur gear 240 or similar drive mechanism to affect rotation of the dispensing member. Details of the preferred drive mechanism will be described in greater detail below. Regardless of the specific drive mechanism, the dispensing member 230 is free to rotate about a longitudinal axis.

[0054] Defined lengthwise along the exterior surface of the dispensing member 230, and parallel to its longitudinal axis is a slot or channel 242 and dimensioned to receive a single one of the pintles retained between the box ends 206, 210. In the preferred embodiment, each box end 206, 210 has converging inner walls 244, 246, the distance between them being wider at the upper end 248 and becoming narrower at the lower end 250 such that at the outlet 252, a single pintle is permitted to pass there through. The outlet 252 at the lower end 250 is positioned directly above the longitudinal slot 242 in the dispensing member 230.

[0055] The magazine 204 is slidably received within a bracket or magazine receiver 260 which is mounted to the table 36. The bracket or receiver 260 is located substantially adjacent the V-shaped channel 86 and is configured to hold the magazine at a predetermined height above the V-shaped channel 86 such that pintles dispensed from the magazine 204 fall to the bottom of the V-shaped channel 86 prior to being inserted into the barrels of the hinge leaves. The bracket or receiver 260 includes a base member 262 attached to the table 36. The base member 262 supports an upright 264, braced at opposing ends with the base member 262 by bulkheads 266 and 268. Attached along the front face 270 of the upright 264 at the opposite vertical sides are gibs 272 and 274, which, together with the upright, define two channels 276 and 278 configured to slidably receive the edges of the back plate 208. The downward movement of the back plate 208 within the gibs 272, 274 is restricted by anyone of a number of different forms of stops. These include a separate piece of bar stock attached to front face 270, or a shoulder machined into the front face, depending upon individual preference. The primary purpose of the stop is to properly locate and fix the dispensing member 230 at the desired height adjacent the V-shaped channel 86. Alternatively, it is contemplated the dispensing member 230 may be separate and apart from the magazine and fixed independently to the bracket 260 so always to be at the proper height and horizontal position. In this configuration, each magazine may have a sliding panel at the bottom which is removed once the magazine is in position. The removal of the slide would permit the pintles to falls, one by one, into the slot formed in the dispensing member.

[0056] Regardless of the specific magazine configuration, it is contemplated an actuator mechanism 280 may be operably coupled to the spur gear 240 to actuate the dispensing member 230 in a rotary fashion to dispense the pintles. Such an actuator is shown generally in FIG. 10 and is mounted to the table 36. The actuator 280 may be coupled to the drive member 240 in any one of a number of different ways, but the preferred method is a direct coupling, either by way of spur gear 282 extending from the actuator 280 and interconnected via an idler gear 284. Alternatively, a similar arrangement could be provided, but rather than gear teeth, each of the gear or rollers could be operably coupled by a friction coupling such as rubber wheels. Other arrangements could also be utilized including belts and the like. As shown in the FIG. 12, the actuator 280 is mounted to an upright 286 which extends from a base 288 attached to table 36. Bulkheads such as 290 may be used to strengthen the connection between the upright 286 and the base 288 similar to the other mounting systems described above.

[0057] The operation of the embodiment shown in FIGS. 9-12 is substantially similar to that described above, but rather than the operator inserting the lead of a continuous length of wire into the feed mechanism, a magazine 204 containing the predetermined size and number of pintles is loaded into the receiver 260 such that upon each sequence of operation, a single pintle is loaded onto the V-shaped channel guide 86. From there, each is driven into the aligned barrels and staked into position as in the previous embodiments.

[0058] One should take notice that in the above description, certain stations are not mentioned to have any operations. The omitted stations are considered to be idle stations in order to provide sufficient separation distance for the various operations being performed on the continuous sheet of steel. The advantages in the aforementioned method specifically include the forming of the holes for the bolts prior to the forming of any contours. This change in procedure substantially reduces deformation in the finished product, provides closer tolerances and better fit. In the prior methods of manufacturing hinges, the contours were often formed prior to the punching of the bolt and locating holes. When the bolt and locating holes were formed, the punching process tended to draw metal into the punches and produce a deformation in the overall contour. As a result, the hinge did not fit well or flush with the underlying substrate.

[0059] The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiment shown in these drawings and described herein are merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by any claims in a subsequent or related application and interpreted according to the principals of patent law, including the doctrine of equivalence. 

We claim as our invention:
 1. An apparatus for assembling interconnecting two leaves of a hinge by automatically inserting and clamping a pin in the barrels of at least two leaves, the combination comprising: a first assembly for holding the two hinge leaves together such that the barrels of the two hinge leaves are aligned; a feed assembly for providing a predetermined length of wire for use as a pintle; and a second assembly for receiving said predetermined length of wire from said feed assembly and driving said predetermined length of wire into the aligned barrels of the two hinge leaves.
 2. The apparatus as defined in claim 1, wherein said first assembly includes: a frame assembly; a press attached to said frame assembly; and a punch and die assembly disposed beneath said press for receiving the two leaves of the hinge.
 3. The apparatus as defined in claim 1, wherein said feed assembly includes: a drive assembly for supplying a predetermined length of wire to said second assembly for use as a pintle; and a wire conditioner assembly for straightening said predetermined length of wire.
 4. The apparatus as defined in claim 1, wherein said feed assembly includes a magazine containing at least one predetermined length of wire to be used as a pintle to be dispensed to said second assembly.
 5. The apparatus as defined in claim 1, wherein said second assembly, includes: a frame assembly; a press attached to said frame assembly; and a shear assembly adjacent and acted upon by said press for receiving said predetermined length of wire and shearing said predetermined length of wire into a pintle.
 6. The apparatus as defined in claim 2, wherein said punch and die assembly, includes: a seat for receiving the two leaves of the hinge in a predetermined configuration; a punch assembly having a housing and a staking tool for engaging the two leaves of the hinge on said seat and compressing predetermined portions of a hinge leaf about said pintle; and an assembly for ejecting the two hinge leaves from the seat.
 7. A method for assembling two leaves of a hinge comprising the steps of: locating and retaining within a first press assembly two leaves of a hinge in a predetermined configuration on a seat such that the barrels of the two hinge leaves are aligned; feeding a predetermined length of wire for use as a pintle to a second press assembly; and receiving said predetermined length of wire from said feed assembly and said second press assembly, and driving said predetermined length of wire into the aligned barrels of the two hinge leaves using a third press assembly.
 8. The method as defined in claim 7, wherein the locating step further includes the steps of: providing a frame assembly for supporting a linear actuator in said first press assembly; and locating the two leaves of the hinge in a punch and die assembly disposed beneath said linear actuator for receiving the two leaves of the hinge.
 9. The method as defined in claim 7, wherein the feeding step includes: drawing a predetermined length of wire from a spool of wire and supplying said predetermined length of wire to said second assembly; and conditioning said predetermined length of wire into a substantially straight configuration by removing any curvature in said length of wire.
 10. The method as defined in claim 7, wherein the feeding step includes providing a magazine containing at least one predetermined length of pintle to be dispensed to said third assembly.
 11. The method as defined in claim 7, wherein said feeding step further includes: supplying said predetermined length of wire to a shear assembly; shearing off said predetermined length of wire to form a pintle; and driving said pintle into the aligned barrels of the two hinge leaves.
 12. The method as defined in claim 8, wherein the step of locating the two leaves of the hinge in a punch and die assembly, includes: positioning the two leaves of the hinge in a predetermined configuration on a seat; urging a housing against the two leaves of the hinge on the seat while driving said predetermined length of wire into the aligned barrels of the two hinge leaves by said third press assembly; and staking predetermined portions of at least one of said two hinge leaves about said predetermined length of wire.
 13. A method for forming a hinge assembly, comprising the steps of: punching a first and second hinge leaves from a piece of stock, each of said hinge leaves having knuckles substantially formed thereon configured to mate with like knuckles on the opposite leave; placing said first and second hinge leaves in a predetermined configuration on a seat; compressing said first and second hinge leaves on said seat between a punch and die such that the knuckles are aligned; ramming a pintle into the aligned knuckles of said first and second hinge leaves when compressed between said punch and die; and staking predetermined ones of said knuckles so as to positively fix said pintle therein.
 14. The method as defined in claim 13, further comprising the steps of: drawing a length of wire from a spool of wire; conditioning said length of wire to remove any curl or bends; feeding said length of wire into a measuring station to define a predetermined length of wire; shearing said predetermined length of wire to form said pintle; and aligning said pintle axially with the knuckles prior to the step of ramming.
 15. The method as defined in claim 13, further comprising the steps of: preforming a plurality of pintles; loading said plurality of pintles into a magazine; placing said magazine into a receiver; and dispensing one of said plurality of pintles into a position axially aligned with the knuckles prior to the step of ramming.
 16. An apparatus for assembling knuckled hinge leaves, comprising: a seat configured to receive a first and second hinge leaves in a predetermined configuration such that the knuckles of each hinge leave are aligned; a punch and die on opposite sides of said seat for placing said first and second hinge leaves in a predetermined and fixed orientation; a first ram adjacent said punch and die for ramming a pintle into the aligned knuckles of said first and second hinge leaves when in said predetermined and fixed orientation; and a second ram adjacent said seat for staking predetermined ones of said knuckles so as to positively fix said pintle therein.
 17. The apparatus as defined in claim 16, further comprising: an assembly for drawing a length of wire from a spool of wire; an assembly for conditioning said length of wire to remove any curl or bends; an assembly for feeding said length of wire into a measuring station to define a predetermined length of wire; an assembly for shearing said predetermined length of wire to form said pintle; an assembly for aligning said pintle axially with the knuckles and with said first ram.
 18. The apparatus as defined in claim 16, further comprising: a magazine for retaining a plurality of pre-formed pintles; a receiver adjacent said first ram for holding said magazine; and a dispensing member for depositing one of said plurality of pintles into a position axially aligned with the knuckles and with said first ram. 